Brush-type embroidery process

ABSTRACT

A brush-type embroidery process, including the steps of placing a first layer of raised filler and a second layer of raised filler, which are made of EVA or foam sheet materials of the like, on a base fabric with the layer of raised fillers covering an area larger than that of the integral pattern to be embroidered; embroidering by a computerized embroidering machine through the first and second layer of raised fillers to the base fabric to present a specifically designed pattern; cutting off the threads in the crevice in-between the first and second layer of raised fillers; and taking away the remaining second layer of raised filler such that the surface stub threads will form a brush-type embroidery due to the second layer&#39;s being removed by force and the surface stub threads&#39; being concomitantly combed by the second layer of raised filler to give the appearance of erect brush bristles.

FILED OF THE INVENTION

[0001] The present invention relates to a process for making abrush-type embroidery having the effect as a brush, such that the raisedeffect is different from those of other plane or extruding embroideries,and is particularly applicable to all kinds of fabric and articles so asto obtain an alternative raised embroidery masterpiece.

DESCRIPTION OF THE PRIOR ART

[0002] There are many kinds of embroideries on general fabric, such asplane embroidery, extruding embroidery, etc. Plane embroidery isdirectly processed on a fabric without adding any filler such that thethread will be stitched through the fabric to appear like a planeembroidery pattern. Extruding embroidery used to be processed bypre-placing a soft foam material on the area to be embroidered andsewing said embroidering area having the soft foam material with thread,so as to accomplish an “extruding” embroidery work.

[0003] Although plane embroidery may present a gradation effect by wayof stitching with the threads of different colors, 3-dimensional effectof the embroidery pattern can yet be obtained. As for extrudingembroidery in the prior art, the raised effect is generally obtained viacovering a soft foam material by threads. It cannot present a3-dimensional effect in fine gradation.

[0004] Both the plane or extruding embroideries mentioned above presentthe embroidery pattern by way of paving threads on the base fabric. Thebrush-type embroidery obtained by the process according the presentinvention can present an embroidery work with an aesthetic feeling outof the ordinary.

SUMMARY OF THE INVENTION

[0005] The primary object of the invention is to provide a brush-typeembroidery process which may obtain an embroidery with the surface stubthreads positioned upward like those of the bristles of a brush, so asto accomplish a gradationally arranged artwork.

[0006] Another object of the invention is to provide an embroideryprocess totally different from the prior art for making plane orextruding embroideries, since the invention can produce a brush-typeembroidery and make mass production much easier.

[0007] To reach the above objects, the present invention includes thefollowing steps:

[0008] (a) placing at least two layers of raised filler on a base fabricwith the fillers covering an area greater than that of the integralpattern to be embroidered;

[0009] (b) embroidering by threaded needle(s) of a computerizedembroidering machine through the at least two layers of raised filler tothe base fabric to present a specifically designed pattern;

[0010] (c) cutting off the threads in the crevice in-between at leasttwo layers of raised filler having a pre-determined thickness; and

[0011] (d) taking away the remaining filler to present an embroideryhaving the effect of brush bristles.

[0012] By way of the above steps, threads vertically extrude from thebase fabric and present a specially arranged embroidery pattern, theintegral visual effect of which appears like brush bristles and presentsan embroidery artwork out of ordinary.

[0013] The detailed contents and other characteristics of the presentinvention can be better understood by way of reading the followingdetailed descriptions with reference to the accompanied drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014]FIG. 1 shows step (a) according to the invention.

[0015]FIG. 2 shows step (b) according to the invention.

[0016]FIG. 3 shows step (c) according to the invention.

[0017]FIG. 4 shows step (d) according to the invention.

[0018]FIG. 5 is a schematic view showing the accomplished brush-typeembroidery processed according to the invention.

[0019]FIG. 6 shows step (c) according to the second embodiment processof the invention.

[0020]FIG. 7 shows step (c) according to the third embodiment process ofthe invention.

[0021]FIG. 8a is a cut-away view of the embroidery accomplished in step(a) according to the invention.

[0022]FIG. 8b is a cut-away view of the embroidery accomplished in step(b) according to the invention.

[0023]FIG. 8c is a cut-away view of the embroidery accomplished in step(c) according to the invention.

[0024]FIG. 8d is a cut-away view of the embroidery accomplished in step(d) according to the invention.

DETAILED DESCRIPTION OF THE EMBODIMENT

[0025] As shown in the drawings, the invention includes the followingsteps:

[0026] (a) placing a first layer of raised filler 20 and a second layerof raised filler 21 on a base fabric 10 with the first layer of raisedfiller 20 on the top of the second layer of raised filler 21, thefillers cover an area greater than that of the integral pattern to beembroidered (as shown in FIG. 1);

[0027] The first layer of raised filler 20 and second layer of raisedfiller 21 can be made of EVA or foam sheet materials or the like, and beselected from a variety range of thicknesses of 1.5, 2.0, 2.5, 3.0, 3.5,4.0 mm and/or other thicknesses within these measurements, depending onthe need in process, while the density of the fillers is adapted to bestitched through by an embroidering needle. To prevent the embroideringthreads from sinking too deep inside of the fillers, a lining materialsuch as a non-woven fabric 22 may be additionally placed on the surfaceof the first layer of raised filler (as shown in FIG. 8a) or the likehaving a sustaining function to make the threads sink in a proper depth.

[0028] (b) embroidering by threaded needle(s) 30 of a computerizedembroidering machine through the first layer of raised filler 20 andsecond layer of raised filler 21 to the base fabric 10 to present aspecifically designed pattern 40 (as shown in FIG. 2);

[0029] In the preferred embodiment according to the invention, thematerial of the upper embroidering threads used in step (b) may be rayonor polyester, while the lower threads may be any kind of threads. By wayof stitching of the pre-determined pattern area, the threads passthrough the fillers to the basic fabric in the corresponding area. Toobtain a better tie up effect for the threads, a paper underlayer 11 canbe further provided beneath the base fabric 10.

[0030] (c) after the embroidery pattern 40 has been accomplished,cutting off the threads in the crevice A in-between the first layer ofraised filler 20 and second layer of raised filler 21 (i.e. theunderside of the first layer of raised filler 20) by a knife 31 (asshown in FIG. 3); and

[0031] After the embroidery pattern has been accomplished, the threadsbeneath the base fabric 10 can be tied up firmly by way of the followingactions:

[0032] 1. applying suitable resin or glue (such as polyvinyl whiteresin) to the threads beneath the base fabric 10 and drying up saidapplicable resin;

[0033] 2. adhering a self-adhesive lining fabric to the undersurface ofthe threads beneath the base fabric.

[0034] (d) as the first layer of filler 20 has been removed by way ofthe previous step, now taking away the remaining second layer of raisedfiller 21 such that the surface stub threads will form a brush-typeembroidery due to the second layer's being removed by force and the stubthreads' being combed by the second layer of raised filler 21 to appeara brush-type embroidery 50 of the effect as a brush (as shown in FIG.5).

[0035] Note that during step (c), when cutting off the threads in thecrevice A in-between the first layer of raised filler 20 and secondlayer of raised filler 21 (i.e. the underside of the first layer ofraised filler 20) by a knife 31 to form surface stub threads 41, besidesthe knife 31 shown in FIG. 3, scissors 32 (as shown in FIG. 6) may beapplied in this step as a cutter. Alternatively, electric cutters suchas electric knife, electric scissors, electric sanders 33 or the likemay be used to cut or grind off the threads on the surface of the firstlayer of raised filler 20 to obtain an embroidery artwork of the sameeffect.

[0036] As shown in FIG. 8a, being a sectional view of the embroideryaccomplished in step (a) according to the invention, the first layer ofraised filler 20 and the second layer of raised filler 21 are piled upon the base fabric 10. To prevent the embroidering threads from sinkingtoo deep inside of the first layer of raised filler 20, a non-wovenfabric may be added onto the surface of the first layer of raised filler21. Besides, a paper underlayer 11 may be provided beneath the basefabric 10 to make the threads tied up firmly without loosing from thebase fabric. Furthermore, in a preferred embodiment according to theinvention, each of the first layer of raised filler 21 and second layerof raised filler 22 may be an inclined or curved board having an unevenheight. For example, if the second layer of raised filler 22 is aninclined or curved plane board having an uneven height, the surface stubthreads of the brush-type embroidery may have uneven height to present aproduct with a vivid effect according to the invention.

[0037] As shown in FIG. 8b, being a sectional view of the embroideryaccomplished in step (b) according to the invention, an embroiderypattern 40 appears on the layers after stitching by threaded needle(s)30.

[0038] As shown in FIG. 8c, being a sectional view of the embroideryaccomplished in step (c) according to the invention, the first layer ofraised filler 20 has been removed due to cutting off of the threads 41,while the second layer of raised filler 21 is still connected with thebase fabric 10.

[0039] As shown in FIG. 8d, being a sectional view of the embroideryaccomplished in step (d) according to the invention, the second layer ofraised filler 21 has been removed by force with the remaining surfacestub threads 41 combed thereby, while the surface stub threads will forma brush-type embroidery 50 and have the appearance of brush bristles.

[0040] Concluded above, the present invention discloses a novelbrush-type embroidery process, which may provide a totally differentvisual effect from the plane and extruding embroideries processedaccording to the prior art. While the threads emerge erectly from thebase fabric as brush bristles, they provide a comfortable feeling intouch and present a 3-dimensional aesthetic feeling visually. Inaddition, as the process according to the invention is simple and neat,it is particularly applicable to mass production and would greatlyreduce the cost in manufacture.

[0041] While certain novel features of this invention have been shownand described and are pointed out in the annexed claims, it is notintended to be limited to the details above, since it will be understoodthat various omissions, modifications, substitutions and changes in theforms and details of the device illustrated and in its operation can bemade by those skilled in the art without departing in any way from thespirit of the present invention.

1. A brush-type embroidery process, including the following steps: (a)placing a first layer of raised filler and a second layer of raisedfiller on a base fabric with the first layer on the top of the secondlayer, the fillers cover an area greater than that of the integralpattern to be embroidered; (b) embroidering by threaded needle(s) of acomputerized embroidering machine through the first and second layer ofraised fillers to the base fabric to present a specifically designedpattern; (c) cutting off the threads in the crevice in-between the firstand second layer of raised fillers; and (d) taking away the remainingsecond layer of raised filler such that the surface stub threads willform a brush-type embroidery due to the second layer's being removed byforce and the surface stub threads' being concomitantly combed by thesecond layer of raised filler to appear the effect of erect brushbristles.
 2. The brush-type embroidery process according to claim 1,wherein the first layer of raised filler and second layer of raisedfiller (interlayer) can be made of EVA material.
 3. The brush-typeembroidery process according to claim 1, wherein the first layer ofraised filler and second layer of raised filler (interlayer) can be madeof foam sheet materials.
 4. The brush-type embroidery process accordingto claim 1, wherein the layer of raised fillers used in step (a) can beselected from a variety range of thickness of 1.5, 2.0, 2.5, 3.0, 3.5,4.0 mm and/or any measurement in between these depending on the need inprocess.
 5. The brush-type embroidery process according to claim 1,wherein during the step (a), to prevent the embroidering threads fromsinking too deep inside of the first layer of raised fillers, a liningmaterial such as a non-woven fabric may be additionally placed on thesurface of the first layer of raised filler for sustaining purposes. 6.The brush-type embroidery process according to claim 1, wherein duringthe step (b), a paper underlayer can be additionally provided beneaththe base fabric to make the embroidering threads tied up firmly.
 7. Thebrush-type embroidery process according to claim 1, wherein during thestep (c), the threads in the crevice in-between the first and secondlayer of raised fillers can be cut off by a knife.
 8. The brush-typeembroidery process according to claim 1, wherein after accomplishing thestep (c), appropriate applicable resin (such as polyvinyl white resin)may be applied to the threads beneath the base fabric and dried up forsetting purposes.
 9. The brush-type embroidery process according toclaim 1, wherein after accomplishing the step (c), resin may be appliedto the threads beneath the base fabric and a fabric lining may befurther adhered onto the threads beneath the base fabric for settingpurposes.
 10. The brush-type embroidery process according to claim 1,wherein after accomplishing the step (c), a self-adhesive lining fabriclining may be adhered to the undersurface of the threads beneath thebase fabric.
 11. The brush-type embroidery process according to claim 1,wherein during the step (a), each of the first and second layer ofraised fillers may be an inclined or curved board having an unevenheight.
 12. The brush-type embroidery process according to claim 1,wherein during the step (c), the threads on the surface of the firstlayer of raised filler may be cut or ground off by manual or electriccutters or sanders.
 13. The brush-type embroidery process according toclaim 1 or 5, wherein during the step (c), the threads on the surface ofthe lining material may be cut or ground off by manual/electric cuttersor sanders.
 14. A brush-type embroidery process, including the followingsteps: (a) placing a sheet of raised filler on a base fabric, the raisedfiller covers an area larger than that of the integral pattern to beembroidered; (b) embroidering by threaded needle(s) of a computerizedembroidering machine through the raised filler to the base fabric topresent a specifically designed pattern; (c) cutting off the threads onthe raised filler; and (d) taking away the raised filler such that thesurface stub threads will form a brush-type embroidery due to the raisedfiller's being removed and the surface stub threads' being concomitantlycombed by the raised filler to appear the effect of erect brushbristles.
 15. The brush-type embroidery process according to claim 14,wherein the raised filler can be made of EVA material.
 16. Thebrush-type embroidery process according to claim 14, wherein the raisedfiller can be made of foam sheet materials.
 17. The brush-typeembroidery process according to claim 14, wherein the raised filler usedin step (a) can be selected from a variety range of thickness of 1.5,2.0, 2.5, 3.0, 3.5 4.0 mm or any measurement in between these, dependingon the need in process.
 18. The brush-type embroidery process accordingto claim 14, wherein during the step (a), to prevent the embroideringthreads from sinking too deep inside of the raised filler, a liningmaterial such as a non-woven fabric may be additionally placed on thesurface of the raised filler for preservation purposes.
 19. Thebrush-type embroidery process according to claim 14, wherein during thestep (b), a paper underlayer can be additionally provided beneath thebase fabric to make the embroidering threads tied up firmly.
 20. Thebrush-type embroidery process according to claim 18, wherein during thestep (c), the threads in the crevice in-between the lining material andthe raised filler can be cut off by a knife.
 21. The brush-typeembroidery process according to claim 14, wherein after accomplishingthe step (c), appropriate resin (such as polyvinyl white resin) may beapplied to the threads beneath the base fabric and dried up for settingpurposes.
 22. The brush-type embroidery process according to claim 14,wherein after accomplishing the step (c), resin may be applied to thethreads beneath the base fabric and a fabric lining may be adhered ontothe threads beneath the base fabric for setting purposes.
 23. Thebrush-type embroidery process according to claim 14, wherein afteraccomplishing the step (c), a self-adhesive lining fabric may be adheredto the undersurface of the threads beneath the base fabric.
 24. Thebrush-type embroidery process according to claim 14, wherein during thestep (a), the raised filler may be an inclined or curved board having anuneven height.
 25. The brush-type embroidery process according to claim14, wherein during the step (c), the threads on the surface of theraised filler may be cut or ground off by manual/electric cutters orsanders.
 26. The brush-type embroidery process according to claim 18,wherein during the step (c), the threads on the surface of the liningmaterial may be cut or ground off by manual/electric cutters or sanders.